Liner apparatus and method for making the same

ABSTRACT

A liner apparatus ( 200 ) and a method ( 600 ) for making the same. The apparatus ( 200 ) can include one or more inserts ( 400 ) and one or more frames ( 300 ). The apparatus ( 200 ) can be implemented for use in a wide variety of different operating environments ( 120 ) utilizing a wide variety of different materials. The apparatus ( 200 ) can be made using a variety of different tools ( 500 ) and processes. Frames ( 300 ) comprised of plastic ( 310 ) or even a foam-like plastic ( 312 ) formed using a super critical fluid (SCF) ( 320 ) can overmolded the inserts ( 400 ). Inserts ( 400 ) can be comprised of non-woven material ( 412 ) and include a hinge area ( 440 ).

RELATED APPLICATIONS

This utility patent application is a continuation-in-part of thefollowing patent applications, all of which are hereby incorporated byreference in their entirety: (a) U.S. utility patent application titled“WHEEL LINER APPARATUS” (Ser. No. 13/705,165) filed on Dec. 4, 2012(“First Application”); (b) PCT patent application titled “WHEEL LINERAPPARATUS” (Application Number PCT/US13/73203) filed on Dec. 4, 2013(“Second Application”); and (c) “WHEEL LINER APPARATUS AND METHOD FORMAKING THE SAME” (Ser. No. 14/720,971) filed on May 25, 2015 (“ThirdApplication”). The Second Application claims priority to the FirstApplication and the Third Application claims priority to the FirstApplication.

BACKGROUND OF THE INVENTION

The invention relates generally to liners used to prevent the intrusionof dust, mud, water, and other forms of debris (collectively “debris”).More specifically, the invention is a liner apparatus (the “apparatus”)and a method of making (the “method”) the apparatus.

Vehicles and other operating environments such as industrial equipmentand structural surfaces can use liner apparatuses for purposes offunction as well as aesthetics.

By way of example, wheel liners in the front of the vehicle can be usedto keep debris from entering the engine compartment while simultaneouslydampening exterior sounds and projecting a desirable aestheticappearance. Wheel liners in the rear of the vehicle and underbody linerscan be used to keep debris outside of the deep body areas of the vehiclewhile dampening sounds and enhancing the appearance of the vehicle. Inthe context of a wheel liner in a vehicle, there are three conventionalapproaches that individually and collectively teach away from the noveland non-obvious wheel liner disclosed in this application.

Traditional Wheel Liner. A traditional wheel liner is typicallycomprised of plastic that is either injection molded or thermoformed.Such a wheel liner is typically attached to the wheel areas of thevehicles through commercially standard attachment configurations.Unfortunately, the traditional wheel liner can result in an unacceptablynoisy experience for human beings in the interior of the vehicle. Suchwheel liners can also be aesthetically unattractive, diminishing thestyling and aesthetic qualities of the vehicle.

Non-Woven Over-Patch. One approach to addressing the problems atraditional wheel liner in the prior art is to add non-woven soundproofing patches on top of the surfaces of the wheel liner. While suchan approach can effectively address the sound and aesthetic issues, theapproach also results in extra weight as well as extra material costs asthe wheel liner possess a double surface for much of the liner. Securelyfastening the non-woven surface over substantially all of thethermoformed plastic wheel liner can complicate the manufacturingprocess and make it substantially more expensive as the conventionalwheel liner can possess a largely irregular surface and the response ofthe underlying plastic frame to heat and other manufacturing processesmay be distinctly different to the fiber or fabric inserts.

Non-Woven Structure. Another alternative approach to the tradeoffsinvolving wheel liners is to replace the plastic structure of the wheelliner in its entirely and instead create a stand-alone structure usingthe non-woven material instead of using patches of such material on topof such a structure. This approach involves a substantially highermaterials and manufacturing cost. Moreover, such an approach raises therequirements of non-standard additional mounting points.

The inventive apparatus can be characterized as a non-obvious hybridcombination of all three of the prior art approaches outlined above. Thecombination is not obvious in light of the prior art for severalreasons. The approach is counterintuitive with respect to the teachingsof the prior art while enjoying synergistic results. For example,modularity is not a goal that the prior art is generally cognizant of inthe context of wheel liners. Prior art manufacturing processes alsoteach away from the hybrid approach of the innovative apparatus. Theprior art does not teach or suggest the process for making theapparatus.

The apparatus is described in greater detail below in the Summary of theInvention section.

SUMMARY OF THE INVENTION

The invention relates generally to liners used to prevent the intrusionof dust, mud, water, and other forms of debris (collectively “debris”).More specifically, the invention is a liner apparatus (the “apparatus”)and a method of making (the “method”) the apparatus.

The apparatus is relatively rigid frame that includes various openingsthat are covered by relatively less rigid inserts. The combination ofelements can allow the apparatus to keep out debris while dampeningnoise.

The apparatus can be implemented using a fully enclosing frame as wellas a partially enclosing frame. The frame can be comprised of plastic,such as a foam-like plastic with a porous structure that results fromusing a combination of a super critical fluid (“SCF”) and a meltedplastic. One or more inserts used to make the apparatus can include ahinge area and a hinge.

The apparatus can be more fully understood upon reading the drawingsthat are discussed briefly below.

BRIEF DESCRIPTION OF THE DRAWINGS

In accordance with the provisions of the patent statutes, the principlesand modes of operation of this invention have been explained andillustrated in preferred embodiments. However, it must be understoodthat this invention may be practiced otherwise than is specificallyexplained and illustrated without departing from its spirit or scope. Noset of drawings can expressly illustrate all of the possible variationsin the shapes, sizes, material composition, and manufacturing process ofthe apparatus.

The following drawings illustrate different examples and embodiments ofthe apparatus:

FIG. 1 a is a block diagram illustrating an example of an apparatusinteracting with an operating environment, with the apparatus beingcomprised of a frame and an insert.

FIG. 1 b is a hierarchy diagram illustrating an example of the differentcategories and subcategories of operating environments that can benefitfrom use of the apparatus.

FIG. 2 a is diagram illustrating an example of a front exploded view ofa liner apparatus and its component frame and inserts.

FIG. 2 b is diagram illustrating an example of a frame without anyinserts.

FIG. 2 c is a diagram illustrating an example of two inserts that areshaped to be used with the frame illustrated in FIG. 2 b.

FIG. 2 d is a perspective diagram illustrating an example of an explodedview of an apparatus comprised of three inserts and two frames, with oneof the inserts including a hinge area and a hinge.

FIG. 2 e is a perspective diagram corresponding with FIG. 2 d, exceptillustrating an example of an assembled view of the apparatus.

FIG. 3 a is a perspective view diagram illustrating an example of anapparatus for use with a front wheel.

FIG. 3 b is a front view diagram illustrating an example of an apparatusfor use with a front wheel.

FIG. 3 c is a diagram illustrating an example of two assemblies that canbe combined and used in the aggregate as a wheel liner apparatus.

FIG. 3 d is a diagram illustrating an example of exploded views of theassemblies illustrated in FIG. 3 c.

FIG. 3 e is a diagram illustrating an example of the bonding between aboundary area on a frame and an overlap area on an insert.

FIG. 4 is a diagram illustrating an example of a tool that can be usedin the manufacture of the apparatus.

FIG. 5 a is a high-level flow chart diagram illustrating an example of aprocess for making the apparatus.

FIG. 5 b is a detailed flow chart diagram illustrating an example of aprocess for making the apparatus.

FIG. 5 c is a flow chart diagram illustrating an example of varioussubsets that can comprise the step of molding the frame around theinsert (i.e. overmolding the frame).

The wheel liner apparatus can be better understood in reference to theDetailed Description section set forth below.

DETAILED DESCRIPTION

The invention relates generally to liners used to prevent the intrusionof dust, mud, water, and other forms of debris (collectively “debris”).More specifically, the invention is a liner apparatus (the “apparatus”or “liner”) and a method of making (the “method”) the apparatus.

All element numbers and their corresponding element names anddescriptions/definitions are listed in Table 1.

I. OVERVIEW

FIG. 1 a is a block diagram illustrating a liner apparatus 200interacting with an operating environment 120. The apparatus 200 iscomprised of a frame 300 and an insert3000. The apparatus 200 can becomprised of a wide variety of different frame 300 and insert3000configurations. One or more frames 300 and one or more inserts3000 canbe configured in a wide variety of different geometries, comprised of awide variety of different materials, and manufactured using a widevariety of different processes.

As illustrated in FIG. 1 b, the apparatus 200 can be implemented for usein a wide variety of different operating environments 120. The apparatus200 was originally conceptualized in the context of a wheel liner 124for an automobile 123. However, the apparatus 200 can also be used inthe context of an underbody 125 for an automobile 125 as well in thecontexts of other types of vehicles 122. Liners 200 can also be usefulin the context of industrial equipment 126 or even structural surfaces128.

Liners 200 can be implemented in a geometry that fits their desiredoperating environment 120. So for example, a liner 200 in the context ofan underbody 125 for an automobile 123 may be more flat than a wheelliner 200. A liner apparatus 200 for a front wheel of an automobile 123will often be larger than a liner apparatus 200 for a rear wheel of anautomobile 123.

A. Frames

The frames 300 of the apparatus 200 are at least relatively more rigidthan the corresponding inserts3000. The frame 300 is intended to providethe necessary rigidity that allows the position of the apparatus 200 tobe secured within the desirable operating environment 120. Frames 300can include one or more attachment components 380 that are used tosecured the apparatus 200 in the desired location within the desiredoperating environment 120. Frames 300 also serve to secure the positionand shape of the inserts3000 in the apparatus 200.

A frame 300 is comprised of interconnected members 360 that create openspaces (openings 370) in which inserts3000 are located. In many of theprocesses that can be used to manufacture the apparatus 200, the frames300 are molded over (i.e. overmolded) the insert3000.

FIGS. 2 a, 2 b, 2 d, 2 e, 3 a, 3 b, 3 c, and 3 d illustrate examples offrames 300 comprised of members 360. FIGS. 2 a, 2 b, and 2 d illustratethe openings 370 in the apparatus 200 that can house the inserts3000.

As illustrated in FIG. 3 e, the frames 300 can mate with thecorresponding inserts3000 by the overlap between the boundary surface390 (which can also be referred to as a mating surface 390) of the frame300 with an overlap surface 470 (which can also be referred to as amating surface 470) of the insert3000. This area can be the only portionof the apparatus 200 in which there is more than one layer to theapparatus 200. The two mating surfaces 390, 470 can represent arelatively small percentage of the surface of the apparatus 200.

The frame 310 can be comprised of a variety of different materials butoften some type of plastic 310. A foam-like plastic 312 with a porousstructure 314 can be a particular desirable material for making theframe 310. A foam-like plastic 312 can be created by combining a gas 322such as Nitrogen gas (N₂) 324, Carbon Dioxide gas (CO₂) 326, or othersimilar gasses 322 with a melted plastic 332 to form a super criticalfluid (SCF) 320 can be cooled to solidify as the frame 300. A smallamount of Nitrogen gas 324 or Carbon Dioxide gas 326 (typically betweenabout 0.001% and about 1% by mass) can be combined with melted plastic310 to form the foam-like plastic 312. Processes for making theapparatus 2000 are illustrated in FIGS. 5 a and 5 c. FIG. 5 cillustrates a process for overmolding the frame 300 through the coolingof a SCF 320.

A foam-like plastic 312 can be associated with a variety of enhancedattributes 340 with respect to plastic 310 which does not have a porousstructure 314. Such attributes 340 can include a reduced mass 341, areduced warp 342, a reduced cycle time 343, a reduced clampingrequirement 344, and an improved sound insulation.

B. Inserts

The majority of the surface of the apparatus 200 can be comprised of oneor more inserts3000. The purpose of the frame 300 is to secure theposition and structural integrity of the inserts3000. The inserts3000provide the primary functionality of blocking debris, dampening sound,and taking up the space/serving as a barrier. As discussed above and asillustrated in FIG. 3 e, the overlap between the inserts3000 and theframe 300 is quite small relative the surface of the apparatus 200.

Inserts3000 can be comprised of a woven material 422 (i.e. a woveninsert 420) as well as a non-woven material 412 (i.e. a non-woven insert412). Inserts3000 can be configured in a wide variety of differentcontours 430, such as shapes that are at least substantially flat (i.e.flat inserts 434) and inserts3000 that are at least substantiallythree-dimensional (i.e, 3-D inserts 432).

Inserts are illustrated in FIGS. 2 a, 2 c, 2 d, 2 e, 3 a, 3 b, 3 c, 3 d,and 3 e. FIGS. 2 d and 2 e illustrate examples of inserts3000 thatinclude a hinge area 440 comprised of a hinge 442. The hinge area 440can provide a means for opening up the geometry of the apparatus 200through the enhanced flexibility. This can make the corresponding tool500 cheaper and easier to build. Moreover, the geometry of the apparatus200 can permit increased complexity with more flexibility in terms ofattachment points. Moreover, this approach can improve the control ofthe manufacturing in manufacturing and installing the apparatus 200.

The increased complexity in terms of part definitions can beparticularly useful in the context of wheel liners 124 and underbodyliners 125.

As collectively illustrated in FIGS. 2 a, 2 c, 2 d, 2 e, 3 a, 3 b, 3 c,3 d, and 3 e, inserts3000 can be comprised of a body 460 and an overlapsurface/mating surface 470 that provides for the overmolding of theframe 300 onto the insert3000. Many embodiments of the inserts3000 willinvolve thermoformed inserts 450.

The frames 300 can be comprised of a porous structure 314 such asfoam-like plastic 312. The foam-like plastic 312 can be created by theuse of a supercritical fluid (SCF) 320 fluid injection feature. Thissubprocess creating a foam-like plastic frame 312 is illustrated in FIG.5 c

II. Automobile Operating Environments

Although the apparatus 200 can be implemented in a wide variety ofdifferent operating environments, vehicles 122 such as automobiles 123are anticipated to be the primary beneficiary of the apparatus 200.

A. Vehicle and Environmental Components

A wide variety of different wheel liner apparatuses 124 can be used inconjunction with a wide variety of different vehicles, such asautomobiles 123. Certain design attributes of the apparatus 200 will beimpacted by the wheel areas of the vehicle on which the apparatus 200 isto be used. In most operational contexts, the apparatuses 200 used inconjunction with the front wheels of the vehicle 122 will be differentthat the apparatuses 200 used in conjunction with the rear wheels of theautomobile 123. The apparatus 200 illustrated in FIG. 1 is intended foruse in conjunction with rear wheels, while the apparatus 200 illustratedin FIG. 5 is intended for use with front wheels. Different vehicles 20will involve different wheel area 32 geometries and otherconfigurations.

The apparatus 200 can be implemented in a manner that is fullycompatible with existing prior art wheel liners such that the apparatus200 can be used to replace prior art wheel liners. Compatibility of theapparatus 200 is achieved by including a compatible mating geometry inthe apparatus 200 to facilitate installment of the apparatus 200 withinthe automobile 123.

1. Automobile

The apparatus 200 can be installed in a wide variety of differentautomobiles 123. Examples of automobiles 123 that can benefit from useof the apparatus 200 include cars, trucks, SUVs, and any other type ofautomobile 123 that uses a prior art wheel liner apparatus. Theapparatus 200 can be particularly desirable in a context whereperformance, weight, aesthetics, noise dampening, shape, modularity, andcost are each important. An area of the automobile 123 in which theapparatus 200 is attached is a wheel area.

2. Wheel Area

The apparatus 200 is applied within the wheel area of an automobile 123.The apparatus 200 can be securely but removeably fixed to the wheel areausing an attachment component 380 or a configuration of multipleattachment components 380 (see FIG. 2 b) on the apparatus 200 that issecured with respect to an connection point in the wheel area of theautomobile 123. As discussed above, the apparatus 200 can be implementedin such a way as to be compatible (i.e. interchangeable) with prior artwheel liner apparatuses with the apparatus 200 because (a) the apparatus200 can possess a shape that is compatible with the wheel area and priorart liners and (b) the apparatus 200 can possess attachment components380 that are compatible with the corresponding connection points in thewheel area.

3. Connection Points

Connection points are connectors in the wheel area of the automobile 123that are designed to mate with the attachment components 380 on theapparatus 200 to securely fix the apparatus 200 to the automobile 123.The apparatus 200 can be configured to be installed in virtually anyprior configuration of connection points. In a preferred embodiment ofthe apparatus 200, conventional “industry standard” connection pointsare used to secure the position of the apparatus 200 with respect to thewheel area. Connection points are typically constructed of a materialsimilar to the material of the attachment components 380, which willoften be some form of plastic. The number of connection points andmating attachment components 380 will typically differ with respect tofront wheel applications and rear wheel applications as well as betweendifferent types of vehicles. Such variations also exist in the priorart, and the apparatus 200 can be implemented in a manner that is fullycompatible with prior art liners and wheel areas.

B. Apparatus and its Component Parts

The apparatus 200 can be implemented in a wide variety of alternativeembodiments for use in a wide variety of different vehicle environments.In many instances, embodiments of the apparatus 200 will differ based onwhether the apparatus 200 is used for the front wheel of the automobile123 (for example, see FIG. 3 b) or for the rear wheel of the automobile123 (for example, see FIG. 2 a).

Although front and rear wheel apparatuses 200 can be configureddifferently with respect to shape, size, geometry, number of openings370, number of attachment components 380, etc. to fit in theirrespective wheel areas, the various elements of the apparatus 200 can bedefined and described generically with respect to both front and rearwheel applications.

As illustrated in FIG. 2 a, the two primary components of the apparatus200 are a frame 300 and an insert 400.

1. Frame

A frame 300 is the substantially rigid body that shapes the apparatus200. In many instances, the frame 300 is comprised of a plastic,typically a thermoformed injection molded plastic. A frame 300 can becomprised of a wide variety of different materials or materialcombinations, but will in most instances be at least relatively morerigid that the material comprising the inserts 400. The frame 300 is asubassembly of various components serving different functions. Asdiscussed above, it can be desirable to make the frame 300 from an SCF320 that is made by adding some gas 322 to a melted plastic 322. Aftercooling, the resulting foam-like plastic 312 can be porous 314 andpossess a variety of desirable enhanced attributes 340.

a. Member

A frame 300 is combination of one or more members 360. In FIG. 2 b, theframe 300 is comprised of three members 360 connected together at thetop and bottom of the frame 300. Rear wheel embodiments of the apparatus200 will typically have between two and four members 360, with apreferred embodiment utilizing three members 360. Front wheelembodiments of the apparatus 200 will typically be comprised of twodistinct subassemblies of members 360, with each subassembly typicallyincluding between two and six members 360.

b. Opening

An opening 370 is a space within the frame 300 between the variousmembers 360 of the frame 300. The opening 370 is the space within theframe that an insert 400 covers. A rear wheel embodiment of theapparatus 200 will typically have two openings 370 and two correspondinginserts 400 with alternative embodiments having a range between about 1and 4 openings 400. A front wheel embodiment of the apparatus 200 willtypically have four openings 370 and four corresponding inserts 400,with alternative embodiments having a range between about 1 and 8openings 370.

c. Attachment Components

One of the functions of the frame 300 is to provide the apparatus 200with the ability to be secured into a fixed position within the wheelarea. An attachment component 380 is a component of the frame 300 thatmates with a corresponding connection point on the wheel area of theautomobile 123. Any prior art technology of securing a prior art wheelliner apparatus on an automobile 123 can be used as an attachmentcomponent 380 for the apparatus 200. A wide variety of differenttechnologies can be incorporated into the apparatus 200 as attachmentcomponents 380. Attachment components 380 allow the apparatus 200 to becompatible with prior art wheel liners because the configuration ofattachment components 380 of the apparatus 200 can correspond to similarmechanisms on prior art wheel liners.

d. Boundary Surface

The apparatus 200 is comprised of a frame 300 that is connected to oneor more inserts 400. A boundary surface 390 is the area on the frame 300that is directly mated with an overlap surface 470 on the insert 40. Thebonding between the boundary surface 390 of the frame 300 and theoverlap surface 470 of the insert 400 keeps the apparatus 200 as aunified whole when the apparatus 200 is installed and used on theautomobile 123. The bonding between the boundary surface 48 of the frame300 and the overlap surface 470 of the insert 400 is typicallyimplemented through the overmolding process used to form the frame 300around the insert 400. Alternatively, a wide variety of bonding agentscan be used. In a preferred embodiment, the frame 300 is overmolded ontothe insert 400. The bonding between the frame 300 and insert 400 canincrease the performance of the apparatus 200.

2. Insert

FIG. 2 c illustrates an example of inserts 400 that correspond to theframe 300 illustrated in FIG. 2 b. An insert 400 (which can also bereferred to as an insert component 400, patch 400 or overlay 400), is acomponent that covers or fills an opening 370 in the frame 300. Inserts400 can be comprised of a variety of different materials, but in apreferred environment, are comprised of a non-woven light texture fabricmaterial. A multi-cavity tool can be used to form the various inserts400 used in a particular embodiment of the apparatus 200. An insert 400can be divided into two subcomponents, an insert body 460 and an insertborder 470 (which can also be referred to as an overlap surface 470).Inserts 400 can be comprised of a wide variety of different materials,including in some embodiments between 3%-60% vegetal renewable fiber ora wide range of different non-woven raw material.

a. Insert Body

The main body 460 of the insert 400 is the portion of the insert 400that does not overlap with the frame 300. The insert body 460 willtypically comprise the vast majority of the insert 50.

b. Overlap Surface

The overlap surface 470 of the insert 400 is the portion of the insert400 that overlaps with the boundary surface 390 of the frame 300. Inmany embodiments, the frame 300 is actually formed directly on theoverlap surface 470 of the insert 400.

III. Advantages Over the Prior Art

The apparatus 200 can be configured and implemented in such a manner asto be perform the function of keeping out mud, water, dirt, snow,stones, water and other debris (collectively the “debris”) outside theengine compartment (in the case of front wheel liners) and deep bodyareas of the vehicle (in the case of rear wheel liners).

The apparatus 200 can also perform the secondary functions of dampeningthe noise perceived from within the occupant area of the automobile 123and while conveying a desirable aesthetic appearance to observerspositioned outside the automobile 123. Rather than seeing mechanicalparts and different components of the automobile 123, such parts andcomponents are tucked in the back of the apparatus 200 that ultimatelyprovides a nice looking, continuous surface. The noise of the wheelsrunning (i.e. turning) is amplified and transferred inside theautomobile 123, therefore the ability of the apparatus 200 to improvethe sound proofing of the inside of the vehicle is material function.

In addition to the considerations mentioned above, there is also anadvantage to reducing weight for components. Use of the apparatus 200 asa replacement for prior art lines allows the apparatus 200 to replaceheavier parts with lighter materials.

The apparatus 200 is an improved solution over the prior art. Theapparatus 200 combines the advantages of prior previous designs whilereducing/eliminating the negative aspects. The hybrid approach for theapparatus 200 is completely inter-changeable with the traditional,plastic-only design and therefore the number of attachment points on thevehicles is unchanged and kept to a minimum (compared with the non-wovenonly solution). The apparatus 200 provides opportunity for weightsavings as most of the part surface is moved from hard plastic towardsthe non-woven material. The apparatus 200 can use rigid material such ashard plastic in key areas allows for the same overall part rigidity andconsistency while allowing for the use of less rigid materials for theinserts 400. As the amount of rigid material is reduced and optimized,the overall cost of the apparatus 200 gets significantly lower than thenon-woven only option.

The apparatus 200 represents an innovative solution pertaining to theinterface between the non-woven inserts 400 and the hard plastic frame300. This interface accommodates over-lapping of the two materials and aconsequential thickness variation. The thickness variation allows forimproved manufacturability of the assembly, compensating for tolerancespread of components as well as positioning variations. Another featurethat can be incorporated into the apparatus 200 pertains to inserthandling and positioning in the over-molding tool 500, allowing theframe 300 to be molded around the applicable insert 400. The innovativeapparatus 200 can be created using a manufacturing process that includesretention features in the mold that allow for proper insert holdingprior to the over-molding cycle.

By using a plastic frame 300 in conjunction with less rigid non-woveninserts 400 the aggregate result for the apparatus 200 is desirabletradeoff between the benefits structural strength and flexibility. Theapparatus 200 can be characterized as a non-obvious combination ofcertain aspects found in existing prior art wheel liners. The apparatus200 is contrasted with the plastic, plastic+patch, and non-woven linersbelow. The manufacturing process that can be used to create a preferredembodiment of the apparatus 200 and prior art teachings regardingconflicting tradeoffs that affirmatively teach away from the apparatus200 render the apparatus both novel and non-obvious.

A. Apparatus vs. Traditional Plastic Wheel Liner

A traditional wheel liner is typically comprised of plastic (“plasticliner”) that is either injection molded or thermoformed. Such a wheelliner is typically attached to the wheel areas of the vehicles throughcommercially standard attachment configurations. Unfortunately, thetraditional wheel liner can result in an unacceptably noisy experiencefor human beings in the interior of the vehicle. Such wheel liners canalso be aesthetically unattractive, diminishing the styling andaesthetic qualities of the vehicle.

Unlike a traditional plastic liner, the apparatus 200 utilizes theplastic material for the frame 300, not the entire apparatus 200. Theopenings on the frame 300 are filled with the non-woven insert 50. Theapparatus 200 can be aesthetically superior, 15-30% lighter, and 2-3 dBless noisy than a traditional plastic liner, while being only 300-60% asexpensive.

B. Apparatus vs. Non-Woven Over-Patch

One alternative prior art approach is the use of non-woven patches ontop of a traditional plastic liner (“plastic+patch liner”). Thenon-woven patches are added on to the traditional apparatus, making thisalternative more expensive and heavier than a traditional plastic liner.While such an approach can effectively address the sound and aestheticissues, the approach also results in extra weight as well as extramaterial costs as the wheel liner possess a double surface for much ofthe liner. Securely fastening the non-woven surface over substantiallyall of the thermoformed plastic wheel liner can complicate themanufacturing process and make it more expensive as the conventionalwheel liner can possess a largely irregular surface and the response ofthe underlying plastic frame to heat and other manufacturing processesmay be distinctly different to the fiber or fabric inserts.

In contrast, the apparatus 200 uses only a plastic frame 300 thatincludes substantial openings 370 covered by non-woven inserts 400. Theapparatus 200 is thus aesthetically equivalent to a plastic+patch linerwhile having 15-30% less mass, a mere 1 dB decrease in sound dampeningcoupled with a 50% reduction in cost.

C. Apparatus v. Non-Woven Structure

Another alternative approach to the tradeoffs involving wheel liners isto replace the plastic structure of the wheel liner in its entirely andinstead create a stand-alone structure using the non-woven materialinstead of using patches of such material on top of a plastic structure(“non-woven liner”). This approach involves a substantially highermaterials and manufacturing cost. Moreover, such an approach raises therequirements of non-standard additional mounting points.

By utilizing a plastic frame 300, the apparatus 200 is 50% lessexpensive than a non-woven structure, while possessing the same sounddampening and aesthetic qualities. The apparatus 200 is somewhat heavierthan an equivalent non-woven liner, but the hybrid design provides forcomplete interchangeability with plastic liners because installment ofthe non-woven liners requires a greater number of attachment componentsand connection points.

D. Additional Attributes of the Apparatus

Varying the geometry of the non-woven inserts 400 allows for greaterflexibility in the manufacturing of the apparatus 200 because the frame300 can be molded around the inserts 400 (i.e. the geometry of theinserts 400 can be specified while keeping in mind the tool position forthe mold over plastic used to create the frame 300). This design inreturn allows for increased manufacturability of the apparatus 200 inregular production environment, eliminating the need for very precise,high tolerance inserts 400. In a preferred embodiment of the apparatus200, there is overlap between the frame 300 and the insert 400. Theoverlapped areas (the overlap surface 470 of the insert 400 and theboundary surface 390 of the frame 300) allow for improved bondingbetween the two materials of the frame 300 and insert 400, increasingthe overall performance of the resulted assembly.

While the attachment components 380 of the apparatus 200 are impacted bycompatibility/interchangeability concerns, the shape and contour of thecomponents of the apparatus 200 can be optimized in order to achievemaximum material yield for the non-woven insert 400. By building amultiple cavity tool for the forming process further cost reductionsbecome possible.

The apparatus 200 can be manufactured in which an insert 400 issubjected to an over-molding process in which the frame 300 is formed.The tool used to manufacture the apparatus 200 can include retentionfeatures built in the core, allowing for precise positioning andretention of the inserts 400 prior to the tool closing.

One advantage of the apparatus 200 is the ability to develop multipledesign alternatives using the same tooling. The design of the apparatus200 is such that first apparatus 200 tool would do forming of theinserts 400 and then consequently take those and insert them into aninjection molding tool, this allows for a large flexibility in terms ofinsert definition. Manufacturers could use various performance materialsand generate different outcome by simply switching between raw materialspecs for the non-woven inserts 400. Manufacturers could also implementinserts 400 that have up to 300-60% vegetal/renewable fiber, again bysimply using a different non-woven raw material.

The design of the apparatus 200 and the manufacturing process used tocreate the apparatus 200 addresses several design and manufacturingrelated issues and solves them: interface between non-woven inserts 400and injection molded frame 300; the geometry of the non-woven inserts400; and the positioning of inserts 400 in the over-molding tool use tocreate the frame 300, a process that enhances repeatability and quality.

It is anticipated that the innovative aspects of the apparatus 200 canalso be applied to other vehicle components, including panels (such asside panels and door panels) and trunk garnish (spare wheel cover) canbe switched towards a somewhat similar frame 300/insert 400 design.

Some embodiments of the apparatus 200 can include additional components.For example, some embodiments of the apparatus 200 can include a softrubber-like edge to eliminate potential rattle noise.

IV. Front Wheel Embodiments

The apparatus 200 can be embodied using a variety of differentmaterials, geometric shapes, and component configurations. In a typicalautomobile, the apparatus 200 used in the front of the automobile 123will be different than the apparatus 200 used in the rear of theautomobile 123. The distinction between front wheel and rear wheelconfigurations is a distinction that exists in the prior art, and thusmust be mirrored by the apparatus 200 if the apparatus 200 is to becompatible and interchangeable with conventional prior art wheel liners.

FIGS. 2 a, 2 b, and 2 c disclose an example of an apparatus 200 suitablefor use on the rear wheels of an automobile 123. The fact that theapparatus 200 is intended for use in a rear wheel location on theautomobile 123 impacts the size and geometry of the apparatus 200 aswell as the number and location of the attachment components 380.However, the different components of the frame 300 and inserts 400 foundin a rear wheel embodiment of the apparatus 200 are also present in afront wheel embodiment of the apparatus 200.

FIG. 3 a is a perspective view illustrating an example of a front wheelembodiment of the apparatus 200. FIG. 3 b is a front view illustrationof a front wheel embodiment of the apparatus 200. In this example, thereare a total of 4 inserts 40, and the frame 300 is comprised of multiplemembers 360. FIG. 3 c is an example of two assemblies 210 that cancomprise a front wheel embodiment of the apparatus 200. Given the largersize of the front wheel apparatus 200, in a preferred embodiment, theapparatus 200 is comprised of two assemblies 210. As illustrated in FIG.3 d, each assembly 210 is comprised of two inserts 50, with each insert400 including an insert body 460 as well as a boundary area 470.Similarly, each frame 300 is comprised of two openings 380 and at least3 members 360.

The overmolding of the frame 300 onto the inserts 400 is theconceptually the same for front wheel liners as it is for rear wheelliners. As illustrated in FIG. 3 e, the boundary surface 390 of theframe is positioned on top of the overlap area 470 of the inserts 400.This design feature is the result of the manufacturing process, and is afeature of both front and rear wheel embodiments of the apparatus 200.

V. Method of Making the Apparatus

The apparatus 200 represents a non-obvious improvement over the priorart in a variety of different respects. Some of the bases fornon-obviousness can be found in the process for manufacturing theapparatus 200. In a preferred embodiment of the apparatus 200, theinserts 400 are created first, and then the frame 300 is subsequentlymolded over the inserts 50.

A. Tool

FIG. 4 is a diagram of a manufacturing tool 500 that can be used toovermold the frame 300 over an insert 400. As discussed above, thecomplexity of the apparatus 200 can be increased if the insert 400includes a hinged area 440 and a hinge 442.

A needle holder 560 in a steel tool 500 can hold a needle 560 thatsecures the position of the non-woven insert 400 with respect to thetool 500. A threaded insert 580 and a die draw 570 can mold a plasticframe 300 around the insert 40. The process for overmolding theapparatus 200 is described below.

A. Example #1

FIG. 5 a is high-level flowchart illustrating an example of a processfor manufacturing the apparatus 200.

At 700, the inserts 400 are created. As discussed above, the inserts 400are preferably comprised of a non-woven material.

At 800, the frame 300 is overmolded over and around the insert 400created at 700.

In some embodiments, the apparatus 200 is an assembled collection ofassemblies 210. In some embodiments, individual assemblies 210 areinstalled in the operating environment 120. In other embodiments, theassemblies 210 are combined into the apparatus 200 prior to installationin the operating environment 120

B. Example #2

FIG. 5 b is a detailed flow chart diagram illustrating an example of aprocess for manufacturing the apparatus 200. There are two overarchingcategories of activities performed in the creation of the apparatus 200.Inserts 400 are formed at 700, and a frame 300 is then overmolded overthe inserts 400 at 800.

At 710, a portion of the raw material used to form the insert 400 is cutfrom a roll. The material is cut to a predefined length that correspondsto the size of the insert 400.

At 720, the cut portion is heated. In order to achieve a permanentpredefined for from a flexible non-woven roll the material must beheated close to the melting point of the non-woven fibers. Differentmaterials will have different melting points, and thus differentmaterials will involve different target temperatures.

At 730, the heated material is placed into a mold. The material iscooled down against a 3-D mold that shapes the material into thegeometric form/contour of the desired insert 400.

At 740, the insert 400 is formed within the mold.

At 750, the formed sheet resulting from the 3-D mold (there could beseveral inserts 400 bundled in the same sheet and a multiple modecavity) is removed from the mold and subjected to a secondary tool fortrimming the formed sheets.

At 760, the inserts 400 are positioned on a predefined table, near theinjection molding machine used to create the frame 300.

At 810, a pre-programmed end of arm tooling selects the inserts 400 fromthe table and prepares them for inserting into the mold tool 500. Theend of the arm tool has grippers on retractable needles.

At 820, the end of arm tool gets inside the overmold tool 500(illustrated in FIG. 4). One part of the tool is used to collectfinished apparatuses 200 (or in some cases subassemblies 210) out of themold. The other side of the end of arm tooling has the new set ofinserts ready for inserting into the tool cavity.

At 830, the inserts 400 are positioned within the injection toolillustrated in FIG. 4. The tool 500 has areas with grippers (i.e.needles 560) inserted into the cavity. This allows for proper andprecise location of the inserts 400 within the tool.

At 840, the tool 500 shuts closed and the plastic is molded around theinserts 400. As melted plastic reaches the non-woven inserts 400 theplastic forms the double layer area of plastic on top of the non-wovenmaterial (i.e. the boundary surface 370 of the frame 300 that overlaysthe overlap area 470 of the insert 400). As discussed above andillustrated in FIG. 3 e, this assures robust bonding of the twodifferent materials of the apparatus 200, and it also assures a nicelooking visible surface for the apparatus 200. This approach and designprovides for a smooth, reliable, and replicable surface for theapparatus 200 as there are no “steps” between the frame 300 and theinsert 400.

Returning to FIG. 5 b, once the frames 300 are solidified in theinjection molding tool, the tool opens and the end of arm tooling isused at 850 to remove the apparatus 200 from the tool and to collect thefinished apparatuses 200. The end of arm tool as well as the extractionsequence of the injection molding tool are designed such that allow fora “one-way” process. The original grippers in the tool provide increasedretention force such that the inserts 400 are detached from the end ofarm and secured on the tool cavity surface. After the overmoldingsequence is completed, the tool ejection system detaches the insertsfrom the needles 560 mounted on the cavity and allow for the end of armrobot grippers to take control over the position of the apparatuses 200.The takeover of control by the end of arm tool is reversible because theangled needles 560 are retractable. One the needles 560 are retractedthe apparatus 200 is no longer sustained by the end of arm robot and canbe placed in the next manufacturing sequence.

The process can be characterized as a complex one-shot injection thatuses automated tools to place the inserts 400 in the overmolding tool500. A complex one-shot injection approach shortens the cycle time whilefacilitating a more reliable working environment.

C. Example of Overmolding Process that uses SCF

FIG. 5 c is a flow chart diagram illustrating an example of anovermolding process 840 that utilizes SCF 320.

At 842, the gas 322 is combined with melted plastic 310 to form the SCP320.

At 844, the SCF 320 is injected into the applicable cavity or cavaties.

At 846, the fluid is allowed to cool, forming the foam-like plastic 312.

VI. Alternative Embodiments

In accordance with the provisions of the patent statutes, the principlesand modes of operation of this invention have been explained andillustrated in preferred embodiments. However, it must be understoodthat this invention may be practiced otherwise than is specificallyexplained and illustrated without departing from its spirit or scope.For example, virtually any prior art variations in different matingconfigurations between attachment components 380 and connection pointscan be incorporated into the apparatus 200. Other prior art variationspertaining to geometric shape, material composition, etc. can also beincorporated into the hybrid approaches embodied in the variousalternative embodiments of the apparatus 200.

Different processes 700, 800 can be utilized to manufacture theapparatus 200, and there are many different variations that can beimplemented into the apparatus 200.

VII. Glossary/Index

Table 1 below discloses a list of element numbers and names.

-   100 System-   120 Operating Environment-   122 Vehicle-   123 Automobile-   124 Wheel Liner-   125 Underbody-   126 Industrial Equipment-   128 Structural Surface-   200 Apparatus-   210 Assembly-   300 Frame-   302 Fully Enclosing Frame-   304 Partially Enclosing Frame-   310 Plastic-   312 Foam-Like Plastic-   314 Porous Structure-   320 Super critical fluid (SCF)-   322 Gas-   324 N₂ gas-   326 CO₂ gas-   332 Melted Plastic-   340 Enhanced Attributes-   341 Reduced Mass-   342 Reduced Warp-   343 Reduced Cycle Time-   344 Reduced Clamping Requirement-   345 Improved Sound Insulation-   360 Member-   370 Opening-   380 Attachment Components-   390 Boundary Surface/Mating Surface-   400 Insert-   410 Non-Woven Insert-   412 Non-Woven Material-   420 Woven Insert-   422 Non-Woven Material-   430 Contour-   432 3-D insert-   434 Flat-   440 Hinge Area-   442 Hinge-   450 Thermoformed Inserts-   460 Insert Body-   470 Overlap Surface/Mating Surface-   500 Tools-   510 Insert Mold-   540 Overmolding Tool-   550 Cavity-   560 Needle-   570 Tie Draw-   580 Threaded Insert-   600 Method of Making-   700 Form Inserts-   710 Cut rolls of insert material-   720 Heat insert material-   730 Insert heated material into mold-   731 Secure the position of the heated material-   740 Form insert in the mold-   750 Trim formed sheet to the desired contour-   760 Position inserts on table-   800 Overmold Frames-   810 Grip inserts-   820 Clear mold-   830 Place inserts in overmolding tool-   840 Mold frame around inserts-   842 Combining a gas with a melted plastic-   844 Injecting the supercritical fluid into a cavity-   846 Allowing the super critical fluid to cool-   850 Remove liner from tools

1. A method (600) for making a liner apparatus (200), said method (600)comprising: forming (700) an insert (400), wherein said insert (400) isnot substantially flat (434); and overmolding (800) a frame (300) ontosaid insert (400).
 2. The method (600) of claim 1, wherein said frame(300) is comprised of a foam-like plastic (312), and wherein said insert(400) is comprised of a non-woven material (412).
 3. The method (600) ofclaim 2, wherein said foam-like plastic (310) is made using a supercritical fluid (320).
 4. The method (600) of claim 3, wherein said supercritical fluid (320) is comprised between about 0.001% to about 1.0% ofat least one of: (a) N₂ gas (324); and (b) CO₂ gas (326).
 5. The method(600) of claim 3, wherein said overmolding (800) said frame (300) ontosaid insert (400) comprises: injecting (844) the super critical fluid(320) into a cavity (550); and ceasing (848) the application of pressureto said super critical fluid (320) while it solidifies into saidfoam-like plastic (312).
 6. The method (600) of claim 1, wherein saidframe (300) is comprised of a foam-like plastic (310) that is comprisedof a solidified super critical fluid (320) that includes a gas (322) anda melted plastic (332).
 7. The method (600) of claim 1, wherein saidovermolding (700) a frame (300) onto said insert (400) includes:gripping (810) the insert (400); removing (820) the insert (400) from aninsert mold (510); positioning (830) the insert (400) into anovermolding tool (540); molding (840) the frame (300) around the insert(400) to make a liner (200) that includes a frame (300) and an insert(400); and removing (850) the liner apparatus (200) from the overmoldingtool (540).
 8. The method (600) of claim 1, wherein the liner apparatus(200) is comprised of more than one insert (400) connected by a hingearea (440).
 9. The method (600) of claim 1, wherein an overmolding tool(540) is used to overmold (800) the frame (300) onto the insert (400).10. The method (600) of claim 9, wherein said overmolding tool (540)includes a cavity (550) for molding (740) the frame (300) and a needle(560) for securing (731) the position of the insert (400).
 11. Themethod (600) of claim 9, wherein said overmolding tool (540) furtherincludes a tie draw (570) and a threaded insert (580) for overmolding(800) the frame (300) onto the insert (400).
 12. The method (600) ofclaim 1, wherein said forming (700) of the insert (400) comprises:cutting (710) rolls of non-woven material (412); and heating (720) therolls of non-woven material (412).
 13. The method (600) of claim 12,wherein said forming (700) of the insert (400) further comprises:inserting (730) the heated non-woven material (412) into an insert mold(510); forming (740) the insert (400) within the insert mold (510); andtrimming (750) the formed sheet (414) into the desired contour of theinsert (400); and positioning (760) the insert (400) for overmolding(800) by an overmolding tool (540).
 14. The method (600) of claim 1,wherein overmolding (800) a frame (300) onto said insert (400) includescombining (842) a gas (322) with a melted plastic (332) to form a supercritical fluid (320).
 15. The method (600) of claim 14, whereinovermolding (800) a frame onto said insert (400) further includes:injecting (844) the super critical fluid (320) into a cavity (550); andallowing (846) the super critical fluid (320) to cool and solidify intosaid foam-like plastic (310).
 16. The method (600) of claim 15, whereinno pressure is applied to the cavity (550) while the super criticalfluid (320) is allowed to cool and solidify into said foam-like plastic(310).
 17. A method (600) for making a liner apparatus (200) comprisedof an insert (400) and a frame (300), said method (600) comprising:forming (700) the insert (400), wherein the insert (400) includes anon-woven material (412) that is not substantially flat (434); andovermolding (800) the frame (300) onto the insert (400) using anovermolding tool (540); wherein forming (700) the insert (410) includes:cutting (710) rolls of non-woven material (412); heating (720) the rollsof non-woven material (412); inserting (730) the heated non-wovenmaterial (412) into an insert mold (510); and forming (740) the insert(400) within the insert mold (510); wherein overmolding (800) the frame(300) onto the insert (400) using the overmolding tool (540) includes:removing (820) the insert (400) from an insert mold (510); positioning(830) the insert (400) into an overmolding tool (540); molding (840) theframe (300) around the insert (400) to make a liner (200) that includesa frame (300) and an insert (400); and removing (850) the liner (200)from the overmolding tool (540).
 18. The method (600) of claim 17,wherein molding (840) the frame (300) around the insert (400) to make aliner apparatus (200) that includes a frame (300) and an insert (400)includes: combining (842) a gas (322) and a melted plastic (332) to forma super critical fluid (320); injecting (844) the super critical fluid(320) into a cavity (550); and allowing (846) the super critical fluid(320) to cool and solidify into said foam-like plastic (310); whereinsaid liner apparatus (200) includes a plurality of inserts (400) thatinclude a hinge area (440).
 19. A liner apparatus (200), said linerapparatus (200) comprising: a plurality of inserts (400), wherein saidplurality of inserts (400) include a non-woven material (412) and atleast one said insert (400) is not substantially flat (434), wherein atleast one said insert (400) includes a hinge area (440); a frame (300),wherein said frame (300) includes a foam-like plastic material (312);wherein said foam-like plastic frame (310) is comprised of a supercritical fluid (320) comprised of a melted plastic (332) and a gas (322)that has been allowed to cool into said foam-like plastic material(312).
 20. The liner apparatus (200) of claim 19, wherein said foam-likeplastic material (312) in said frame (300) possesses a plurality ofenhanced attributes (340) relative to said plastic (310), wherein saidplurality of enhanced attributes (340) include: (a) a reduced mass(341); (b) a reduced warp (342); (c) a reduced cycle time (343); (d) areduced clamping requirement (344); and (e) an improved sound insulation(345).